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I used egg crate and pond foam to create the structure. I then glued sand to the exterior and attached rocks with zip ties. Part of the cave is made with PVC. I have some pics to show the building process if you would like to see them.
Looks fantastic! setup a fugue to help reduce algae growth in your display and the only thing you will have to worry about is coralline algae which is what you want.
I just finished building a rock structure for a 180 gallon tank that I recently bought. Attached is a picture of it. I used PVC to form a skeleton of the arches and then drilled holes in the rock so that I could slide the rocks over the PVC. I then used pond foam to cover the cracks in-between the rocks to hide the PVC and used sand and epoxy to make the pond foam look like the rocks.
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